U.S. patent application number 11/040037 was filed with the patent office on 2005-06-16 for facing for insulation and other applications.
This patent application is currently assigned to Venture Tape Corp.. Invention is credited to Cohen, Lewis S., Maria van Beukering, Sebastianus Franciscus.
Application Number | 20050129896 11/040037 |
Document ID | / |
Family ID | 32654436 |
Filed Date | 2005-06-16 |
United States Patent
Application |
20050129896 |
Kind Code |
A1 |
Cohen, Lewis S. ; et
al. |
June 16, 2005 |
Facing for insulation and other applications
Abstract
A method and material for covering exposed insulation surfaces
to protect them from moisture and other environmental factors. The
covering typically includes a first, exposed layer of a
metal-containing foil, a second layer of a metal-containing foil, a
layer of a polymer disposed between the first two layers of foil, a
third layer of a metal-containing foil, and a second layer of
polymer disposed between the second and third layers of foil. A
layer of a pressure sensitive adhesive is applied to one of the
exposed layers of foil, and the pressure sensitive adhesive layer
is covered with a release liner prior to application. The foil
provides the necessary moisture and weather seal while the polymer
provides the necessary strength and puncture resistance. The
overall thickness of the laminate typically is less than 100
microns, permitting it to be easily cut and manipulated at the job
site while providing an effective, long lasting weather seal.
Inventors: |
Cohen, Lewis S.; (Needham,
MA) ; Maria van Beukering, Sebastianus Franciscus;
(Gouda, NL) |
Correspondence
Address: |
WOLF GREENFIELD & SACKS, PC
FEDERAL RESERVE PLAZA
600 ATLANTIC AVENUE
BOSTON
MA
02210-2211
US
|
Assignee: |
Venture Tape Corp.
Rockland
MA
|
Family ID: |
32654436 |
Appl. No.: |
11/040037 |
Filed: |
January 21, 2005 |
Related U.S. Patent Documents
|
|
|
|
|
|
Application
Number |
Filing Date |
Patent Number |
|
|
11040037 |
Jan 21, 2005 |
|
|
|
10330162 |
Dec 27, 2002 |
|
|
|
Current U.S.
Class: |
428/40.1 ;
156/213; 156/71; 428/354; 428/458 |
Current CPC
Class: |
Y10T 428/31678 20150401;
Y10T 428/14 20150115; Y10T 428/31786 20150401; F16L 59/029
20130101; Y10T 156/1077 20150115; Y10T 428/24967 20150115; Y10T
428/269 20150115; Y10T 428/2848 20150115; B32B 15/08 20130101; F24F
13/0263 20130101; Y10T 428/31681 20150401; Y10T 156/103
20150115 |
Class at
Publication: |
428/040.1 ;
428/354; 428/458; 156/071; 156/213 |
International
Class: |
B32B 009/00 |
Claims
What is claimed is:
1-16. (canceled)
17. A method for protecting insulation from damage due to moisture
and other environmental factors, said method comprising: providing
a covering material having a metal-containing layer on one surface
and a layer of a pressure sensitive adhesive on a second, opposite
surface, said covering material including at least one layer of a
puncture resistant material disposed between the metal-containing
layer and the adhesive layer; manually cutting from the covering
material an appropriately sized first sheet at a job site; removing
a release liner covering the pressure sensitive adhesive layer of
the first sheet; applying the first sheet to the insulation so that
the adhesive layer bonds to the insulation and the metal-containing
layer is exposed; and applying additional sheets of covering
material directly to the insulation such that each sheet of
covering material overlaps sheets of covering material directly
adjacent thereto.
18. The method as recited in claim 17 wherein said manually cutting
step comprises cutting the covering material into sheets having
shapes that conform to an external shape and size of the insulation
being covered.
19. The method as recited in claim 17 further comprising, for a
pipe having a curved portion, wrapping lengths of a pressure
sensitive adhesive tape having a layer of a metal-containing foil
and a layer of a puncture resistant polymer about the sheets of
covering material to conform the covering material to the
configuration of the pipe.
20. The method as recited in claim 17 further comprising sealing
seams between adjacent sheets of covering material with a pressure
sensitive adhesive tape.
21. The method as recited in claim 17 wherein the covering material
is formed of a laminate of aluminum foil, and polyester in
multiple, alternating layers.
22. The method as recited in claim 17 wherein for an insulated duct
having a substantially rectangular cross-sectional shape, the first
and second applying steps comprise: applying the first sheet of
covering material to a bottom wall of the duct so that an
overlapping portion of the sheet extends upwardly along each side
wall of the insulated duct immediately adjoining the bottom wall;
thereafter applying a cut sheet of covering material to each side
wall of the insulated duct so that each sheet on the side wall
overlaps the overlapping portion of the first sheet extending
upwardly from the bottom wall and so that another overlapping
portion of each sidewall sheet of material extends beyond the side
wall and along the top wall of the insulated duct; and applying a
fourth sheet of a covering material to the top wall of the duct to
overlap the overlapping portions of the sheets of material on the
side wall which extend along the top wall.
23-28. (canceled)
Description
FIELD OF THE INVENTION
[0001] This invention relates generally to insulation products for
use with fluid conduits, such as pipes or ducts, and more
particularly, to a facing material for use with insulation
surrounding fluid conduits for providing a vapor barrier and a
weather seal.
BACKGROUND OF THE INVENTION
[0002] Pipes or duct work in dwellings, commercial buildings and
industrial plants are used for heating or air conditioning purposes
and therefore carry fluids, such as heated or cooled air, or steam.
In industrial applications, pipes or duct work also may carry
chemicals or petroleum products or the like. Such pipes our duct
work and associated heating or air conditioning units typically are
covered with an exterior layer of insulation. The duct work
typically is formed of aluminum or steel, while the pipes may be
formed of any suitable material, such as copper, steel, aluminum,
plastic, rubber or other like materials.
[0003] The insulation used to cover such pipes or duct work and
associated heating and air conditioning units often includes
fiberglass or mineral wool, foamed cellular glass or a rigid foam,
covered by a jacket of foil or a layer of paper, such as kraft
paper. Other layers of materials may be included in the insulation
jacket, such as a layer of foil, a scrim, or a layer of polyester.
Duct board is often used to cover duct work.
[0004] When such pipes or duct work are in a location exposed to
weather or when they are in other environments where the exterior
insulation surface is subject to degradation by moisture or the
like, it is common to cover the insulation with a facing. This is
particularly true for insulation having an exterior layer of paper
or for duct board, (whether or not the surface is a metalized layer
or a paper layer) to protect the insulation from moisture, sun,
wind or other weather elements.
[0005] In one existing example, sheet metal cladding is applied to
the exterior surface of the insulation. Such cladding typically is
formed of aluminum, stainless steel, galvanized steel, or another
like metal. This cladding has certain drawbacks including the fact
that such cladding is very expensive and time consuming to install.
In addition, metal cladding is not water or vapor tight or
weatherproof because of joints, any repairs can be quite costly,
prefabrication of the cladding is required off site, and metal
cladding is very heavy and therefore difficult to handle.
[0006] Another existing solution is to cover the insulation with
butyl rubber. However, this solution also has drawbacks including
the fact that the butyl rubber does not perform well and tends to
delaminate, particularly in extreme weather conditions. Butyl
rubber also is very difficult to apply because it is messy to cut
and form, and it is very heavy. Moreover, butyl rubber has been
known to cause delamination of the outer surface of the insulation
from the fiberglass or the wool disposed in the interior because of
its weight and because of its lack of strength at elevated
temperatures. A butyl rubber covering tends to have a poor
appearance, and does not perform well at temperatures below zero
degrees Fahrenheit or above 120.degree. Fahrenheit and therefore
should not be used in extreme weather environments where such
exterior coverings are most desired and are often necessary. Butyl
rubber also tends to creep, has a poor fire and smoke rating, and
therefore is not UL listed. Finally, solvents are required to
activate butyl rubber at temperatures below 45.degree. F.
[0007] It is also known to cover insulation with thin layers of
aluminum foil using a butyl rubber adhesive. However, such
coverings have little or no puncture resistance and the adhesive
layer has the same drawbacks noted above, including a tendency to
run or ooze at elevated temperatures.
[0008] Scrim and mastics are also used to cover insulation.
However, the use of such materials often is very labor intensive
and requires a multiple step process. These products can only be
applied during certain weather conditions, and it is very difficult
to regulate the thickness of mastic to make it uniform.
Consequently, such products have very limited applications, and
generate a poor appearance.
[0009] Another known product is bitumen felt and netting. This
product is very labor intensive to apply and is not recommended for
exterior use. It also has a very poor fire rating, and is
unsightly. Thus, its use is very limited.
[0010] In view of the foregoing, there exists a need for a material
or facing for covering insulation, particularly exterior
insulation, that is relatively inexpensive, easy to apply, provides
a good appearance and provides the desired vapor and weather seal.
There also is a need for a product which is fire resistant, has low
maintenance costs and can be used in extreme temperature
conditions.
SUMMARY OF INVENTION
[0011] This invention relates generally to a facing material for
application to exposed surfaces of insulation or other like
materials to provide a vapor seal and to protect the insulation
from weather related damage. The facing of this invention overcomes
the drawbacks of the prior art systems discussed above, since it is
relatively inexpensive, is easy to apply, provides a good
appearance, is easily cut and manipulated at the job site and
provides a 100% vapor seal. The facing of this invention also can
be applied and will maintain its integrity in extreme weather
conditions and is very fire resistant. This invention also relates
to a method for applying a facing to insulation.
[0012] In one aspect, the invention includes a facing for
insulation. One embodiment of the facing includes a first layer of
a metal-containing foil, a second layer of a metal-containing foil,
a third layer of a metal-containing foil, and a first layer of a
puncture resistant polymer film disposed between the first and
second layers of foil, and a second layer of a puncture resistant
polymer film disposed between the second and third layers of foil.
In another embodiment, a layer of pressure sensitive adhesive is
applied to the third layer of foil. In yet another embodiment, at
least the first layer of metal-containing foil may be formed of
aluminum. In another embodiment, at least the first layer of the
puncture resistant polymer film is formed of polyester. A typically
thickness for the metal-containing foil layers is about 9 microns,
while a typical thickness of the puncture resistant polymer film
layers is about 23 microns or greater, although the polymer film
layers could be as thin as 5 microns.
[0013] In another aspect, a weather seal for use on exposed
surfaces is disclosed. This weather seal includes a first layer of
an aluminum foil, a second layer of a metal-containing foil, a
third layer of a metal-containing foil, a first layer of a puncture
resistant material disposed between the first layer of aluminum
foil and the second layer of metal-containing foil, a second layer
of a puncture resistant material disposed between the second and
third layers of metal-containing foil and a layer of a pressure
sensitive adhesive disposed on the third layer of metal-containing
foil. In one embodiment, the first and second layers of puncture
resistant material are formed of polyester. In another embodiment,
the combined thickness of the weather seal is less than 100
microns. In another embodiment, the second and third layers of
metal-containing foil are formed of a metalized foil.
[0014] In another aspect, a covering for exterior and interior
insulation is disclosed. This covering includes a first layer of
aluminum foil having a thickness in the range of from about 5
microns to about 50 microns, a first layer of polyester adhered to
the first layer of aluminum foil with an adhesive, the polyester
layer having a thickness greater than about 23 microns, a second
layer of aluminum foil adhered to the first layer of polyester
material by an adhesive, the second layer of aluminum foil having a
thickness in the range of from about 5 microns to about 50 microns,
a second layer of polyester material adhered to the second layer of
aluminum foil by an adhesive, the second layer of polyester
material having a thickness greater than about 23 microns, a third
layer of aluminum foil adhered to the second layer of polyester
material by an adhesive, the third layer of aluminum foil having a
thickness in the range of from about 5 microns to about 50 microns,
and a pressure sensitive adhesive layer disposed on the third layer
of aluminum foil.
[0015] In yet another aspect of the invention, a covering for
insulation is provided which includes multiple layers of a
metal-containing foil and multiple layers of a puncture resistant,
polymer film. The layers of puncture resistant polymer film are
alternated with the layers of a metal-containing foil. The covering
also includes a layer of a pressure sensitive adhesive disposed on
one side of the covering, and on the other, exposed side of the
covering, a layer of material resistant to ultraviolet radiation,
acid rain, and salt. The covering is sufficiently flexible that it
may be conformed to the shape of an insulated pipe.
[0016] In another aspect, a method for protecting insulation from
damage due to moisture and other environmental factors is
disclosed. This method includes the step of providing a covering
material having a metal-containing layer on one surface and a layer
of a pressure sensitive adhesive on a second surface, as well as a
layer of a puncture resistant material disposed between the
metal-containing layer and the adhesive layer, cutting the covering
manually at a job site to form a first sheet, removing the release
liner covering the pressure sensitive adhesive on the first sheet,
applying the first sheet to the insulation so that the adhesive
layer bonds to the insulation and the metal-containing layer is
exposed, and applying additional sheets of covering material
directly to the insulation such that each sheet of covering
material overlaps sheets of covering material directly adjacent
thereto.
[0017] In one embodiment, the method is used for covering an
insulated duct having a substantially rectangular cross-sectional
shape. In this embodiment, the applying steps include applying the
first sheet of covering material to a bottom wall so that at least
a three inch portion extends upwardly along each sidewall, applying
a cut sheet of covering material to each side wall of the insulated
duct so that it overlaps the portion of the sheet along the bottom
wall which extends upwardly along the side wall, and so that a
portion of the sheet material along each side wall extends along
the top wall, and applying a fourth sheet of covering material to
the top wall to overlap the portions of the sheets along the side
wall which extend along the top wall.
[0018] In another embodiment of the invention, where the pipe to be
insulated has a curved portion, lengths of a pressure sensitive
adhesive tape having a metal-containing foil layer and a puncture
resistant polymer layer are wrapped about the sheets of covering
material to conform the covering material to the configuration of
the pipe.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] The objects, advantages and features of this invention will
be more clearly appreciated from the following detailed
description, when taken in conjunction with the accompanying
drawings, in which:
[0020] FIG. 1 is a cross-sectional view of a cutaway portion of one
embodiment of the facing of this invention;
[0021] FIG. 1A is a cross-sectional view of a cutaway portion of
another embodiment of the facing of this invention;
[0022] FIG. 1B is a cross-sectional view of a cutaway portion of
yet another embodiment of the facing of this invention;
[0023] FIG. 2 is a cross sectional schematic view of rectangular
duct work illustrating a method for applying the facing of FIG. 1
to duct work:
[0024] FIG. 3 is a perspective schematic view illustrating a method
for applying the facing of FIG. 1 to a cylindrical, straight
pipe;
[0025] FIG. 4 is a perspective, schematic view illustrating a
method for applying the facing of FIG. 1 to a curved pipe;
[0026] FIG. 5 is a perspective, schematic view illustrating a
method for applying the facing of FIG. 1 to a reduced portion of
rectangular duct work;
[0027] FIG. 6 is a perspective, schematic view illustrating a
method for applying the facing of FIG. 1 to a reduced pipe;
[0028] FIG. 6A is a plan view of a precut facing segment to be
applied to a tapered portion of a reduced pipe;
[0029] FIG. 7 is a perspective schematic view illustrating a method
for applying the facing of FIG. 1 to a T-section pipe;
[0030] FIG. 7A is a plan view of precut facing segments to be
applied to a T-section pipe; and
[0031] FIG. 8 is a cross-sectional view of a cutaway portion of a
wrapping tape to be used in the method of this invention.
DETAILED DESCRIPTION
[0032] With reference now to the drawings, and more particularly to
FIG. 1 thereof, one embodiment of the facing structure of this
invention will be described. Facing 10 includes multiple layers of
a metal or metalized foil and a puncture-resistant polymer film
which are laminated together. The layers of foil provide the
desired vapor seal, weather resistance, and a desirable exterior
appearance. The layers of polymer provide puncture and tear
resistance, particularly with respect to birds and other animals.
All of the materials together provide the desired fire resistance
and resistance to flame spread.
[0033] The number of layers of foil and polymer, the thickness of
each layer, and the actual materials forming the layers are chosen
to provide a facing which optimizes each of the desired properties.
For example, thick layers of metal would provide additional
resistance to weathering, impermeability to moisture, resistance to
puncture, and additional strength. However, if the metal layers
become too thick, they cannot be easily cut and manually applied at
the job site. The material also could become too heavy to be easily
manipulated, conformed and applied by the average worker.
Similarly; additional layers of a polymer film, or greater
thicknesses of polymer film would increase the puncture resistance
of the facing but could also increase the weight, reduce the
conformability and render cutting more difficult, thus making it
very difficult to apply at the job site and to conform it to the
shape of the fluid conduits about which it is to be wrapped. Any
failure to conform the facing closely to the shape of the
insulation surrounding the conduit could produce gaps through which
moisture or wind could enter, thus destroying the weather and vapor
seal and permitting the damage to the insulation it is designed to
prevent. Different materials also provide different advantages. For
example, steel provides greater strength and puncture resistance,
while aluminum is lighter in weight, cheaper, more easily cut and
more flexible. A metalized foil is lighter in weight than most
metal foils, but generally is not as strong or as impermeable to
moisture. Polytetrafluoroethylene (PTFE) is water proof, but is
hard to cut and expensive. Polyester is cheaper and easier to cut
and use than PTFE.
[0034] The embodiment illustrated in FIG. 1 represents a
consideration of all of these factors and a balancing of the
desired properties to achieve an optimal result. This embodiment
includes a first layer 12 of a metal-containing foil, a layer 14 of
a polymer film, another layer 16 of a metal-containing foil,
another layer 18 of a polymer film, and a third layer 20 of a
metal-containing foil. A pressure sensitive adhesive layer 22 is
disposed adjacent foil layer 20. Prior to application, pressure
sensitive adhesive layer 22 is covered by a release liner 24.
[0035] Layers 12, 16 and 20 typically are formed either of a
metalized foil or of a metal foil. In one embodiment, layers 12, 16
and 20 are formed of an aluminum foil. It is understood however,
that other metal foils could be used for layers 12, 16 and 20, such
as a stainless steel foil, a titanium foil, a copper foil, or the
like. In another embodiment, foil layers 12, 16 and 20 are formed
of a metalized foil. Metalized foils suitable for use in this
invention include conventional, commercially available foils in
which a metal, such as aluminum, steel or titanium, is vapor
deposited on a substrate formed of a polymer, such as polyvinyl
fluoride (sold under the name TEDLAR.RTM.), polyethylene or
biaxially oriented polypropylene. Since metalized foils tend to
have pin holes resulting from handling during manufacture or other
causes, it is preferred that not all of layers 12, 16 and 20 be
formed of a metalized foil. Preferably, at least one of layers 12,
16 and 20 is formed of a metal foil, such as aluminum. In a
preferred embodiment, at least layer 12 is formed of a metal foil,
although it is understood that layer 12 could be formed of a
metalized foil, so long as one of layers 16 and 20 is formed of a
metal foil. If only one of layers 12, 16 and 20 is formed of a
metal foil, it is preferred that such a layer have a thickness of
at least nine microns to provide the desired impermeability to
moisture. If more than one of layers 12, 16 and 20 is formed of a
metal foil, it is preferred that the total thickness of metal foil
layers in facing 10 be at least nine microns, and more preferably
25 microns.
[0036] Layers 14 and 18 typically are formed of a polyester film
although other polymer films such as polypropylene, polyethylene,
polyurethane, Nylon.RTM., Dacron.RTM., Kevlar.RTM., or
polytetrafluoroethylene could be used.
[0037] Layers 12, 14, ,16, 18 and 20 preferably are laminated or
bonded together such as by an adhesive. This laminating adhesive
could be a pressure sensitive adhesive or any conventional, flame
retardant adhesive which is suitable for laminating a metal foil to
a polymer, and which has high strength and durability. In one
embodiment, a conventional urethane laminating adhesive is used,
such as that, sold under the name Boscadur and purchased from the
Bostik Chemical Division of the Emhart Fastener Group in Middleton,
Mass. 01949. Another adhesive is sold under the name Adcote by Rohr
& Haas. Typically, these laminating adhesives are provided in
layers of about 0.3 to 2.0 mils and coating weights of about 3 to
11 pounds per 1000 square feet.
[0038] Layer 22 of a pressure sensitive adhesive can be any
commercially available, pressure sensitive adhesive that is
suitable for bonding to a metal or metalized foil and to kraft
paper or other insulation surfaces, and which maintains its
integrity under low and high temperature conditions. Examples of
such suitable pressure sensitive adhesives are disclosed in U.S.
Pat. No. 4,780,347, which is specifically incorporated herein by
reference. In particular, one suitable adhesive is a pressure
sensitive, acrylic adhesive, which when cured, approaches a 100%
acrylic compound in which substantially all solvents have been
removed. This adhesive can, however, tolerate up to 1% solvents
after curing and still perform as desired. When cured, layer 22
formed of this particular acrylic adhesive typically has a
thickness of between about 1.0 and 5 mils and a coating weight of
about 5.5 to about 27.5 pounds per 1000 square feet. This
particular acrylic adhesive is especially desirable, since it
remains tacky and useable at temperatures as low as minus
17.degree. Fahrenheit and as high as 284.degree. Fahrenheit.
[0039] Release liner 24 can be any conventional release liner
suitable for use with an acrylic adhesive. A typical release liner
is a silicone coated, natural kraft paper release liner rated at 70
pounds per ream.
[0040] In one embodiment, where foil layers 12, 16 and 20 are
formed of a metal foil, each layer 12, 16 and 20 is about 9 microns
in thickness. However, especially for aluminum foils, thicknesses
as low as 5 microns also would be suitable for many applications,
while thickness as great as 50 microns would be acceptable, since
facing 10 would still be cuttable with a knife or scissors and
would still be sufficiently conformable to be used in covering most
types of installations in most applications.
[0041] In one embodiment, layers 14 and 18 may be about 23 microns
or greater in thickness. However, it is to be understood that
layers 14 and 18 could be thinner than 23 microns, depending upon
the degree of puncture and tear resistance desired. In fact, layers
14 and 18 could be as thin as 5 microns for certain applications.
In addition, these layers 14 and 18 may also be as thick as 50
microns so long as the resulting facing 10 is still adequately
conformable to the shape of the fluid conduit and the insulation
surrounding it, and the facing 10 could still be cut with scissors
or a knife. Preferably, the total thickness of facing 10 is 100
microns or less to allow it to be easily cut and handled at the job
site. If the facing could be precut at the factory prior to
transportation to the job site, much thicker layers of polymer and
foil could be utilized to provide enhanced performance as long as
the material still conformed to the outer shape of the
insulation-covered conduit.
[0042] In one embodiment in which layers 12, 16 and 20 are formed
of an aluminum foil having a thickness of about 9 microns, and in
which layers 14 and 18 are formed of a polyester film having a
thickness of about 23 microns, the total thickness of facing 10,
not including adhesive layer 22, is about 85 microns. This
thickness includes the thicknesses of the laminating adhesives used
to bond together the layers. In this embodiment, a typically
thickness of adhesive layer 22 is about 0.079 millimeters with a
coating weight of about 50 grams per square meter. The peel
adhesion is about 30 ounces per inch and the sheer adhesion is
indefinite at 2.2 pounds per square inch. The tensile strength
measured according to PSTC-31 is about 50 pounds per inch width.
The elongation at break is at about 166%. The puncture resistance
according to ASTM D-1000 is about 16 kilograms, while the tear
strength according to ASTM D-624 is about 2 kilograms. A maximum
temperature for continuous use is about 300.degree. Fahrenheit
(149.degree. C.), and the application temperature ranges from minus
17.degree. Fahrenheit to 284.degree. Fahrenheit (minus 27.degree.
C. to plus 140.degree. C.). Facing 10 has no permeability to water
vapor. Facing 10 has a chemical and ultraviolet resistance which is
comparable to that of aluminum.
[0043] FIGS. 1A and 1B illustrate other embodiment of the facing 10
of this invention. Like numbers are used for like parts, where
appropriate. In FIG. 1A, a protective layer 26 is disposed on top
of layer 12 of facing 10. Protective layer 26 protects layer 12,
and thus all of the layers below layer 12 from damage caused by the
environment. Preferably, protective layer 26 protects against
damage due to ultraviolet radiation, and/or acid rain, and/or salt
and/or other corrosive materials found in the environment. In one
embodiment, protective layer 26 is a cured epoxy coating which is
deposited on layer 12 while wet and allowed to cure. Other
materials which could be used for layer 26 include a urethane
material, polyvinyl fluoride, an acrylic material, a metalized film
of polyvinyl fluoride, a metalized titanium film, a layer of silica
vapor deposited upon layer 12 or layer of Saran.RTM..
[0044] In another embodiment, as illustrated in FIG. 1B, facing 10
could be provided without adhesive layer 22 or release liner 24. In
the absence of adhesive layer 22, a user could apply facing 10
directly to insulation at the factory prior to shipment to a job
site. In such an instance, the facing 10 could be applied utilizing
a conventional hot melt adhesive, or any other standard adhesive.
If facing 10 of FIG. 1B is sent directly to the job site, the user
could apply facing 10 to the insulation utilizing a mastic, or
conventional adhesive, which is either applied to layer 20, or
which is applied to the insulation prior to application of the
facing 10.
[0045] Another alternative embodiment of the structure of FIG. 1 is
illustrated in FIG. 1A in which an additional layer 15 is
incorporated into the structure of FIG. 1 between a layer 12 of a
metal-containing foil and a layer 14 of polymer film. This
additional layer 15 can be incorporated-between any two layers in
the structure, but typically is not disposed on an outside surface,
or adjacent adhesive layer 22. This layer could be formed of a
fiberglass scrim, a polyester scrim, a woven fabric or a fiberglass
and a polyester scrim. The woven fabric could be formed of a
polypropylene or a polyester thread. Such a layer 15 provides
additional tensile strength, and tear resistance. In addition, a
scrim layer produces a pattern on the exterior surface of facing 10
that is rectangular in shape, and that aids the installer in
properly aligning the facing 10 on the insulation.
[0046] Moreover, additional layers of a metal-containing foil and a
polymer could be added to the structure of FIG. 1 so long as the
resulting product were sufficiently conformable, easy to cut and
lightweight. Additional layers could be accommodated by making
thinner the alternating metal-containing layers and polymer layers.
In addition, it is to be understood that layer 22 of a pressure
sensitive adhesive could be applied to polymer layer 18 rather than
to a metal-containing layer, as illustrated in FIG. 1.
[0047] Methods of use of facing 10 in various applications will now
be described with reference to FIGS. 2-7. Before applying the
facing 10 to any surface, it is important that the surface be dry,
clean and free from dust, oil and grease or silicone. Facing 10
should be cut to size prior to application. Typically, cutting to
size is performed at the jobsite so that the worker can measure the
fluid conduit or duct work on the spot and cut the facing to the
precise size desired. However, facing 10 could be precut at the
factory, particularly for the portions used on curved pipes, as
shown in FIG. 4, or on T-sections, as shown in FIG. 7. Typically,
facing 10 comes in large rolls which are unrolled and then cut with
scissors, knives, box cutters or the like. It is important that the
sheets of facing 10 be applied in an overlapping fashion, to
provide a weather and vapor proof seal. A three inch (75
millimeter) overlap is recommended. When applying sheets of the
facing 10, typically release liner 24 is peeled back from one edge
and creased to expose adhesive layer 22 along that edge. This edge
is then adhered to the surface to which the facing is to be
applied, and thereafter, release liner 24 is peeled away from
adhesive layer 22 as the facing is applied, such as by use of a
spreader which smoothes the facing and the insulation surface.
[0048] One method for applying a sheet of facing 10 to rectangular
duct work 30 is illustrated in FIG. 2. Typically, a sheet 32 of
facing 10 is first applied to the bottom wall 31 of the duct 30 and
the necessary overlap 34 is provided along walls 33 and 35.
Typically, one edge of sheet 32 is first adhered to wall 33 or 35
to provide overlap 34, while the remainder of the sheet 32 remains
covered by release liner 24. As sheet 32 is secured to wall 31,
release liner 24 is peeled away from adhesive layer 22 just prior
to adhering sheet 32 to wall 31. The process continues until all of
wall 31 is covered, and the necessary overlap 34 is provided along
the other of wall 33 or 35. Thereafter, another sheet 36 or 38 of
facing is applied along respective wall 33 or 35. In both
instances, the overlap 34 typically is provided along wall 37. Once
walls 33 and 35 have been covered, top wall 37 is covered in the
manner previously-described with sheet 40. Sheet 40 need not
overlap walls 33 and 35. Typically, no additional sealing tape is
required for such rectangular duct work 30, or the like. This
process is repeated along the entire axial or longitudinal length
of the duct work 30 with additional sheets of facing 10 that
overlap adjacent sheets in a longitudinal direction along
circumferentially extending edges. This technique is particularly
advantageous for large, flat horizontal ductwork upon the top wall
37 of which water tends to pool. By using a sheet on the top wall
37 that extends the width of the wall and overlaps walls 33 and 35,
there are no seams into which the pooled water may seep.
[0049] An example of a method of application of this facing 10 to a
straight circular pipe 48 is illustrated in FIG. 3. In this
example, a series of sheets 52 having the same width and length are
cut from rolls of the facing 10 prior to installation. Each sheet
52 is sized so that when wrapped about the insulation 46 on pipe
48, a suitable circumferential overlap 50 results along axially
extending edges. Similarly, when successive sheets 52 are applied,
there should be an overlap 54 between each successive sheet 52 in
an axial direction along circumferentially extending adjacent
edges. Each sheet 52 is otherwise applied in the same manner as
described with respect to FIG. 2.
[0050] FIG. 4 illustrates one example of application of facing to a
curved pipe 64. Initially, sheets 60 are applied in a manner
virtually identical to sheets 52 of FIG. 3. Successive sheets 60
are cut and applied in an overlapping manner to insulation 62 along
the axial length of pipe 64. One difference between the method of
FIG. 3 and that of FIG. 4 is that the sheet 60 applied to the
curved portion 66 of pipe 64 typically would be narrower in width
in an axial direction than sheets 60 covering the straight portion
of the pipe 64, since facing 10 may not conform as easily to the
shape of the curved portion 66 of the pipe 64 as it does to the
straight portions because of a slight inherent rigidity caused by
the multiple layers of foil and polymer.
[0051] To assist in conforming sheet 60 to the shape of the curved
portion 66 of the pipe 64, in some applications, it may be
desirable to apply a wrapping of a tape 68 at axially spaced
intervals, as shown. Tape 68 typically is wrapped so as to overlap
itself circumferentially and should be applied at whatever axial
intervals are necessary to conform sheet 60 to the shape of curved
portion 66. A tape 68 typically used for this purpose is a tape
which has the same vapor barrier, weathering characteristics, and
appearance as facing 10. In one example, as shown in FIG. 8, tape
68 is formed of a film 28 of a polymer disposed between two layers
27 and 29 of a metal-containing foil. The layers are laminated
together using a laminating adhesive, like that used for facing 10.
Like layers 12, 16 and 20 of facing 10, layers 27 and 29 could be
formed of a metalized foil or a metal such as aluminum, while the
polymer film 28 can be formed of the same materials as layers 14
and 18 of facing 10, such as polyester. Layers 27 and 29 and
polymer film 28 could be of the same construction and thickness as
respective layers 12 and 14 found in facing 10. Typically, a
pressure sensitive adhesive layer 25, similar to adhesive layer 22,
is disposed on layer 29, and a release liner 23, such as release
liner 24 is applied to the layer 25 of pressure sensitive
adhesive.
[0052] FIG. 5 illustrates one example of the application of facing
10 to a reduced section of duct work 69. A first trapezoidal
segment of facing is cut and applied to surface 70. This
trapezoidal segment should provide the desired overlap on each
adjoining surface, including surfaces 74, 76, 78 and 80. Next,
trapezoidal segments of facing are cut for surfaces 74 and 80,
providing the necessary overlap along adjoining surfaces 70, 86, 88
and 82. Thereafter, a final trapezoidal segment of facing is cut
and applied to surface 82 with overlap provided along surfaces 90,
84, 80 and 74. Next, sheets are cut having the necessary
circumferential length to be wrapped about surfaces 76, 88 and 90
with the necessary axial overlap along circumferential edges as
well as with the necessary overlap with each of the trapezoidal
segments on surfaces 70, 80, 82 and 74 and adjacent sheets in an
axial direction along circumferentially extending edges. Finally,
sheets of facing are cut to be wrapped about surfaces 78, 84 and 86
to provide the necessary overlap with the trapezoidal segments on
surfaces 80, 82, 74 and 70, with adjoining sheets in an axial
direction along surfaces 84, 86 and 78, and with-themselves in an
axial direction along circumferentially extending edges. Each sheet
is applied as previously described.
[0053] FIG. 6 illustrates one example of the application of facing
10 to a reduced pipe 99. Typically, a sheet of facing is first
applied to surface 100 which is the reduced portion 101 of the pipe
99 just adjacent the tapered portion 102. A sheet of facing is cut
and wrapped about surface 100 in the manner previously described.
Thereafter, a C-shaped section 105 of facing (see FIG. 6A) is cut
and applied to the tapered portion 102, providing overlap with the
material on surface 100. Sheets of facing 10 then are cut and
applied to surface 104 of the enlarged portion 103 of the pipe 99.
These sheets are applied one adjacent another along the length of
surface 104 so as to provide overlap with each other in an axial
direction and to provide overlap with themselves as shown in a
circumferential direction. Finally, sheets of facing are applied to
surface 106 in overlapping relationship with one another along the
axial length, and with themselves in a circumferential direction,
as previously described.
[0054] FIGS. 7 and 7a illustrate one example of the application of
facing 10 to a T section of a pipe 116. A first sheet 110 is cut
having the configuration shown in FIG. 7a. Sheet 110 is provided
with cutouts 112 to accommodate the T section 114,of pipe 116.
Thereafter, a sheet 120 is cut to the shape shown in FIG. 7a. Sheet
120 is then applied to section 114 in the manner shown, so that
there is overlap between edge 122 of sheet 120 and edge 124 on
sheet 110. Thereafter, additional overlapping sheets may be applied
to segment 114, as well as to portion 126, as previously described
with respect to a straight pipe in FIG. 3. Preferably a length of
tape 128, like tape 68, is applied at the junction of edges 122 and
124 to effect a vapor tight seal.
[0055] The facing 10 of this invention, when used with insulation
for a fluid conduit, such as a pipe or duct work, provides a vapor
tight seal about the insulation and duct work or pipe that is
weather resistant, puncture and tear resistant, sufficiently
flexible, easily cut, and aesthetically pleasing. Facing 10 can be
applied in almost all weather conditions, and in a temperature
range from minus 17.degree. to plus 284.degree. Fahrenheit. The
resulting sealed pipe or duct work is fire resistant, and any flame
would spread very slowly. Facing 10 can be easily repaired onsite,
and has a long life.
[0056] The method of this invention provides an easy technique for
applying facing to insulation disposed on duct work or on pipes and
can be mastered with very little training or skill. Installation is
fast, clean and safe. Only scissors and a knife or the like are
required as tools, and all work can be done at the job site. No
prior or cuffing or assembly is required.
[0057] Modifications and improvements will occur within the scope
of this invention to those skilled in the art. The above
description is intended as exemplary only, the scope of this
invention being defined by the following claims and their
equivalents.
* * * * *